Compressed polymer impregnated backing material abrasive articles incorporating same, and processes of making and using

Abstract

This invention relates to compressed composite backing materials (e.g., compressed polymer impregnated backing substrates) and coated abrasive articles that include such compressed composite backing materials. This invention also relates to methods of making and using said compressed composite backing materials and coated abrasive articles. The claimed processes and systems related to the use and manufacturing of coated abrasive articles are improved and cost effective.

What is claimed is: 
     
       1. An abrasive article comprising:
 a compressed composite backing material comprising a compressed backing substrate impregnated with a polymeric composition, wherein the polymeric composition comprises and epoxy composition, a phenolic composition, or a combination thereof, and wherein the compressed composite backing substrate comprises a spun lace fabric having a total weight within a range from 50 to 600 grams per meter squared; and 
 an abrasive layer disposed on the compressed composite backing material. 
 
     
     
       2. The abrasive article of  claim 1 , wherein the polymeric composition comprises an epoxy composition. 
     
     
       3. The abrasive article of  claim 1 , wherein the polymeric composition comprises a phenolic resole composition. 
     
     
       4. The abrasive article of  claim 3 , wherein the phenolic resole composition comprises a first phenolic resole resin. 
     
     
       5. The abrasive article of  claim 4 , wherein the phenolic resole composition further comprises a second phenolic resole resin. 
     
     
       6. The abrasive article of  claim 4 , wherein the first phenolic resole resin comprises a formaldehyde to phenol ratio in a range of 1.6 to 1.8, a gel time at 121° C. in a range of 8-12 minutes; and a water tolerance in a range of 430 to 500%. 
     
     
       7. The abrasive article of  claim 5 , wherein the second phenolic resole resin comprises a formaldehyde to phenol ratio in a range of 1.6 to 1.8, a gel time at 121° C. in a range of 8-12 minutes; and a water tolerance in a range of 400 to 480%. 
     
     
       8. The abrasive article of  claim 1 , wherein the amount of the polymeric composition comprises 200 g/m 2  to 1000 g/m 2 . 
     
     
       9. The abrasive article of  claim 1 , wherein the compressed composite backing material has a tensile strength in a machine direction in a range of not less than 1 kgf/25 mm and not greater than 150 kgf/25 mm and a tensile strength in a cross direction in a range of not less than 1 kgf/25 mm and not greater than 100 kgf/25 mm. 
     
     
       10. The abrasive article of  claim 9 , wherein the compressed composite backing material has a tensile strength in the machine direction and in the cross direction of not less than 10 kgf/25 mm. 
     
     
       11. The abrasive article of  claim 1 , wherein the compressed composite backing material has a total thickness in a range from 0.5 mm to 5 mm. 
     
     
       12. The abrasive article of  claim 1 , wherein the compressed composite backing material has a flexural modulus in a machine direction in a range of 1 GPa to 7 GPa and a flexural modulus in a cross direction in a range of 0.5 GPa to 5 GPa. 
     
     
       13. The abrasive article of  claim 1 , wherein when the abrasive article is placed in a climate chamber at a temperature of 35° C. and 85% relative humidity (RH) for 2.5 hours has a % weight gain of less than 1.4 wt %. 
     
     
       14. The abrasive article of  claim 1 , wherein when the abrasive article is placed in a climate chamber at a temperature of 35° C. and 85% relative humidity (RH) for 2.5 hours has a three-point dimensional stability where all three points have a % change in dimension of less than 120%. 
     
     
       15. An abrasive article comprising:
 a compressed composite backing material comprising a compressed backing substrate impregnated with a polymeric composition, wherein the polymeric composition comprises a first phenolic resole resin and a second phenolic resole resin, and 
 an abrasive layer disposed on the compressed composite backing material. 
 
     
     
       16. The abrasive article of  claim 15 , wherein the compressed backing substrate comprises a nonwoven fabric, and wherein the nonwoven fabric is a spun lace fabric, a stitch bonded fabric, or a combination thereof. 
     
     
       17. The abrasive article of  claim 16 , wherein the nonwoven fabric is a stitch bonded fabric comprising at least 2 webs and not greater than 10 webs. 
     
     
       18. The abrasive article of  claim 17 , wherein the stitch bonded fabric has a total weight in a range from 50 to 1600 grams per meter.